Nanocomposite thermoplastic resin composition with flame resistance

Abstract

The present invention relates to a nanocomposite thermoplastic resin composition with flame resistance comprising a basic resin mixture, which comprises a rubber-modified styrene-containing graft copolymer, a thermoplastic polyamide resin and a styrene-containing copolymer, a compatibilizer, a melamine based flame retardant and an organic layered silicate. The nanocomposite thermoplastic resin composition of the present invention offers superior flame resistance without comprising a halogen based flame retardant.

1. A nanocomposite thermoplastic resin composition with flame resistance consisting essentially of:
 a) 100 parts by weight of a basic resin mixture comprising 1-75 wt % of a rubber-modified styrene-containing graft copolymer, 20-95 wt % of a thermoplastic polyamide resin and 5-80 wt % of a styrene-containing copolymer; 
 b) 0.1-15 parts by weight of a compatibilizer; 
 c) 5-30 parts by weight of a melamine based flame retardant; and 
 d) 0.01-10 parts by weight of an organic layered silicate, 
 wherein the styrene-containing copolymer consists essentially of 50-80 wt % of at least one compound selected from the group consisting of styrene, α-methylstyrene and nucleus-substituted styrene and 20-50 wt % of at least one compound selected from the group consisting of acrylonitrile, methyl methacrylate and butyl acrylate. 
 
     
     
       2. The nanocomposite thermoplastic resin composition of  claim 1 , wherein the rubber-modified styrene-containing graft copolymer comprises 10-60 wt % of at least one rubber selected from the group consisting of polybutadiene, styrene-butadiene copolymer, polyisoprene and butadiene-isoprene copolymer, 30-80 wt % of at least one graft monomer selected from the group consisting of styrene, α-methylstyrene and nucleus-substituted styrene and 10-60 wt % of at least one graft monomer selected from the group consisting of acrylonitrile, methyl methacrylate and butyl acrylate. 
     
     
       3. The nanocomposite thermoplastic resin composition of  claim 1 , wherein the thermoplastic polyamide resin comprises a polymer having a relative viscosity of 1.5-5.0. 
     
     
       4. The nanocomposite thermoplastic resin composition of  claim 1 , wherein the compatibilizer is at least one selected from the group consisting of a styrene-maleic anhydride copolymer, an acrylonitrile-butadiene-styrene-maleic anhydride grafting copolymer (ABS-g-MA), methyl methacrylate (MMA) and an acrylonitrile-styrene-maleic anhydride grafting copolymer (AS-g-MA). 
     
     
       5. The nanocomposite thermoplastic resin composition of  claim 1 , wherein the melamine based flame retardant is at least one selected from the group consisting of melamine, melamine cyanurate, melamine phosphate, melamine pyrophosphate and melamine polyphosphate. 
     
     
       6. The nanocomposite thermoplastic resin composition of  claim 1 , wherein the organic layered silicate is selected from the group consisting of montmorillonite, hectorite, vermiculite and saponite which has been organified by an organifying agent selected from the group consisting of alkyl ammoniums, alcohols having a degree of polymerization of 5-1,000 and ketones. 
     
     
       7. The nanocomposite thermoplastic resin composition of  claim 1 , which further comprises a lubricant, a heat stabilizer, an antioxidant, a photostabilizer, a dripping retardant, a pigment and an inorganic filler. 
     
     
       8. A nanocomposite thermoplastic resin composition with flame resistance comprising
 a) 100 parts by weight of a basic resin mixture comprising 1-75 wt % of a rubber-modified styrene-containing graft copolymer, 20-95 wt % of a thermoplastic polyamide resin and 5-80 wt % of a styrene-containing copolymer; 
 b) 0.1-15 parts by weight of a compatibilizer; 
 c) 5-30 parts by weight of melamine cyanurate as a flame retardant; and 
 d) 0.01-10 parts by weight of an organic layered silicate.